EP0475434A2 - Polymer composition and its use - Google Patents

Polymer composition and its use Download PDF

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Publication number
EP0475434A2
EP0475434A2 EP91115553A EP91115553A EP0475434A2 EP 0475434 A2 EP0475434 A2 EP 0475434A2 EP 91115553 A EP91115553 A EP 91115553A EP 91115553 A EP91115553 A EP 91115553A EP 0475434 A2 EP0475434 A2 EP 0475434A2
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EP
European Patent Office
Prior art keywords
polymer composition
weight parts
polymer
butenic
inorganic filler
Prior art date
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Application number
EP91115553A
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German (de)
French (fr)
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EP0475434B2 (en
EP0475434A3 (en
EP0475434B1 (en
Inventor
Haruhiko C/O Mitsui Petrochemical Ind.Ltd Tanaka
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Mitsui Chemicals Inc
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Mitsui Petrochemical Industries Ltd
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Classifications

    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0076Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00Use of inorganic substances as compounding ingredients
    • C08K3/01Use of inorganic substances as compounding ingredients characterized by their specific function
    • C08K3/013Fillers, pigments or reinforcing additives
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00Macromolecular materials of the coating layers
    • D06N2203/04Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/042Polyolefin (co)polymers
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00Properties of the materials
    • D06N2209/16Properties of the materials having other properties
    • D06N2209/1628Dimensional stability
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/23907Pile or nap type surface or component
    • Y10T428/23979Particular backing structure or composition
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/23907Pile or nap type surface or component
    • Y10T428/23993Composition of pile or adhesive

Definitions

  • This invention relates to a polymer composition containing a poly 1-butene resin as a resin component and its use. More detailedly, this invention relates to a polybutene-1 polymer composition containing a large amount of a filler, which composition is excellent in flexibility and dimensional stability and does not generate poisonous gas if it burns, and a sheet made of the composition. This invention further relates to a flexible sheet suitable, for example as a backing material for carpets, etc.
  • tile type carpets having a side of the order of 30 to 50 cm were developed. These tile type carpets have various advantages, for example, that they are easy even for non-professionals to install, they can easily be storaged and repaired, and moreover, it is also possible to give a preferred design by changing the arrangement of tile type carpets having a different colors and designs.
  • tile type carpets are at least required to possesses the characteristics of the following 1 to 3.
  • the temperature of carpets changes over a fairly wide range of from about -5 °C up to about 40 °C depending on the seasons of winter and summer.
  • tile type carpets have a large linear expansion coefficient, there arise, due to temperature change over such a fairly wide range, inconveniences, for example that gaps arise from the contraction of the carpets at the low temperature time of winter, whereas at the high temperature time of summer they partly rise; and therefore desirably they have a small linear expansion coefficient.
  • Polyvinyl chloride sheets containing calcium carbonate in a high concentration which have hitherto been used as a backing material of carpets can satisfy the above characteristics 1 and 2, but are insufficient in the point of the above 3 because they generate chlorine gas or hydrogen chloride gas by combustion. Therefore, materials are demanded which do not generate poisonous gas by combustion.
  • 1-butenic polymers are known to be resins capable of containing a large amounts of a filler, and it is proposed that 1-butenic polymer compositions containing a large amount of a filler can be used, for example as laminates of magnetic tapes, plastic porcelains, floor covering materials or wall covering materials (Refer to Japanese Laid-Open Patent Publication No. 31550/1985).
  • composition essentially consisting of (a) 5 to 50 weight % of an ethylene-containing copolymer, (b) 2 to 15 weight % of a process oil and 50 to 90 weight % of a filler is proposed, and this composition is proposed to be utilized for sound deadening sheet, carpets having back conating, particularly automotive carpets (Refer to Japanese Laid-Open Patent Publication No. 71734/1980 and US Patent No. 4,263,196).
  • the object of this invention lies in providing a poly(1-butene) resin composition containing a large amount of a filler which is excellent in moldability, flexibility and dimensional stability, and suitable as a raw material of flexible sheets which do not generate poisonous gas by combuston; and a sheet made of it.
  • Another object of this invention lies in providing a tile type carpet having excellent characteristics hereinabove described.
  • the 1-butenic polymer (A) as a polymer component of the compositon of the invention is a homopolymer of 1-butene or a copolymer of 1-butene with another ⁇ -olefin having 2 to 20 carbon atoms.
  • another ⁇ -olefins having 2 to 20 carbon atoms include, for example, ethylene, propylene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-tetradecene, 1-octadecene, etc.
  • One or two or more of these other ⁇ -olefins can be contained in the 1-butenic polymer (A) in a copolymerized form.
  • the content is usually 20 mole % or less, preferably 10 mole % or less.
  • the melt flow rate (MFR) of the 1-butenic polymer (A) is such that when the resulting composition is extrusion molded, melt extrusion becomes easy and moldability becomes good, and is 0.01 to 150 g/10 min, preferably 0.05 to 50 g/10 min.
  • melt flow rate is a value measured according to ASTM D 1238, E.
  • the ratio (Mw/Mn) of weight average molecular weight (Mw) to number average molecular weight (Mn) denoting the molecular weight distribution of the 1-butenic polymer (A) is usually in the range of about 2 to about 15, and is preferably in the range of about 3 to about 8 in view of excellence in moldability and mechanical strength.
  • the isotactic index (I.I.) as an index of its stereoregularity is 80 % or more, and is preferably 90 % or more in view of excellence in dimensional stability.
  • This isotactic index (II) is a index measured, by the following method.
  • the polymer composition of the invention contains a large amount of the inorganic filler (B), as mentioned above.
  • This inorganic filler (B) may be one usually used as a filler for various polymers and may be in a form of powder, flake, short fiber, whisker on the like. Further, the inorganic filler may be any of naturally produced one or the one treated or artificially synthesized one.
  • the average diameter is about 10 to about 1,000 micrometers preferably about 50 to about 500 micrometers.
  • it is fibrous it is suitable that it is short fiber having a length of about 7 mm or less, preferably about 5 mm or less.
  • the inorganic filler (B) are, for example, magnesium carbonate, calcium carbonate, clay, kaolin, bentonite, talc, silica, mica, diatom earth, quartz sand, pumice powder, slate powder, asbestos, alumina white, barium sulfate, lithopone, calcium sulfate, molybdenum disulfide, graphite, glass fiber, glass globes, foamed glass globes, fly ash, volcanic glass hollow bodies, synthesized inorganic hollow bodies, single-crystal potassium titanate, carbon black, carbon fiber, carbon hollow bodies, anthracite culm, artificial rock crystal; hydroxides of magnesium, calcium, etc.; vermiculite, graphite; metals such as iron, aluminum and zinc and their oxides; ferrite, etc.
  • magnesium hydroxide carbon black, ferrite, mica, talc and calcium carbonate all in the form of powder since they can afford a sheet having further excellent flexibility and smaller linear expansion coefficient.
  • the hydrocarbonic oil (C) in the polymer composition of the invention is liquid at ordinary temperature and may be either one that occurs in nature or synthesized one.
  • Preferred ones among the hydrocarbonic oils (C) are those having compatibility with the 1-butenic polymer, and particularly those having a kinematic viscosity of 30 to 600 cSt (centistokes) at 40°C.
  • Specific examples of the hydrocarbonic oil (C) are, for example, oils comprising paraffinic, naphthenic or aromatic hydrocarbons and mineral oils which are a mixture of the above hydrocarbons; cooligmers of ethylene and an alpha olefin; liquid polybutene, and squalane. These are used alone or in a combination of two or more. Preferred among them are paraffinic process oils and liquid polybutene.
  • the ratio of the above component (B) to the component (A) contained in the polymer composition of the invention is a ratio of 95 to 60 weight parts, preferably 93 to 70 weight parts of the inorganic filler (B) to 5 to 40 weight parts, preferably 7 to 30 weight parts of the 1-butenic polymer (A) in view of the balance of flexibility and linear expansion coefficient.
  • the ratio of the hydrocarbonic oil (C) contained in the polymer composition of the invention is 2 to 20 weight parts, preferably 5 to 15 weight parts per 100 weight parts in total of the 1-butenic polymer (A) and the inorganic filler (B) in view of giving good extrusion moldability and flexibility and causing no inconvenience, for example that the oil bleeds on the resin surface.
  • the polymer composition of the invention can also contain, in a range such that the object of the invention is not spoiled, a thermoplastic resin (D) other than 1-butenic polymers such as polyethylene, polypropylene, polystyrene or an olefinic elastmer, aiming at the improvement of moldability or the adjustment of various physical properties.
  • a thermoplastic resin (D) other than 1-butenic polymers such as polyethylene, polypropylene, polystyrene or an olefinic elastmer, aiming at the improvement of moldability or the adjustment of various physical properties.
  • the polymer composition of the invention can contain, if necessary, in a range such that the object of the invention is not spoiled, additives such as an antioxidant, an ultraviolet absorber, a fungicide, a rustinhibitor, a lubricant, a filler, a pigment and a heat resistant stabilizer.
  • additives such as an antioxidant, an ultraviolet absorber, a fungicide, a rustinhibitor, a lubricant, a filler, a pigment and a heat resistant stabilizer.
  • a granular or pelletized polymer composition can be obtained, for example by mixing the 1-butenic polymer (A), the inorganic filler (B) the hydrocarbonic oil (C) and the thermoplastic resin (D), and if necessary, the above various additives in a conventional mixer such as a Henschel mixer, and melting and kneading the mixture using an extruder.
  • a conventional mixer such as a Henschel mixer
  • a sheet made of the above polymer composition and a carpet wherein such a sheet is used as a backing material The thickness of the sheet is 1 to 5 mm, preferably 2 to 3 mm.
  • the sheet can be molded from the polymer composition according to a method known per se .
  • the molding can be carried out according to a conventional method such as, for example, extrusion molding, injection molding or press molding.
  • the carpet is prepared by a method wherein a sheet having a thickness of about 1 to 3 mm is continuously molded by extrusion molding and at the same time laminated with a carpet.
  • the polymer composition and a sheet made thereof according to the invention can suitably be used not only as a backing material for carpets, but as a tube material for feed water and drain, a covering material for electric bulbs, and the like.
  • the tensile Young's modulus (kg/cm2) and linear expansion coefficient (10 ⁇ 5/°C) of the sheets were measured according to the following methods. Further, the bending test was carried out according to the following method.
  • the measurement was made according to JIS K 7113.
  • Tensile Young's modulus is a value used as an index of the rigidity of a sheet, and when this value is high, the sheet is hard, and when the value is low, the sheet is soft. When tensile Young's modulus is 5,000 kg/cm2 or more, the sheet is inferior in flexibility and unsuitable as a backing material for carpets.
  • thermomechanically analyzing apparatus produced by Seiko Denshi Kogyo Co., Ltd., TMA 100.
  • the linear expansion coefficient is 15 x 10 ⁇ 5 (1/°C) or less.
  • the brittleness of a sheet 3 cm wide, 20 cm long and 3 mm thick was investigated by bending it by hand.
  • the 1-butenic polymer (A), the inorganic filler (B) and the hydrocarbonic oil (C) were mixed in the compounding ratio shown in Table 1 by a Henschel mixer, melted and kneaded at a molding temperature of 200°C using a biaxial extruder, and molded into a sheet having a thickness of about 3 mm by the press molding method. According to the above methods, the resulting sheet was measured for tensile Young's modulus and linear expansion coefficient, and further subjected to the bending test to judge the brittleness of the sheet. The results are shown in Table 1.
  • the polymer composition according to this invention is excellent particularly in flexibility and dimensional stability, and suitable as a material of flexible sheets which do not generate poisonous gas even if they are burned. Further, the sheet of the invention made of this polymer composition has such excellent characteristics as above and is particularly suitable as a backing material for tile type carpets.

Abstract

A polymer composition substantially comprising
  • (A) 5 to 40 weight parts of a 1-butenic polymer,
  • (B) 95 to 60 weight parts of an inorganic filler,
  • (C) a hydrocarbonic oil in an amount of 2 to 20 weight parts per 100 weight parts in total of the above (A) and (B), and
  • (D) a thermoplastic resin other than 1-butenic polymers in an amount of 0 to 20 weight parts per 100 weight parts in total of the above (A) and (B).

Description

    〈Detailed Description of the Invention〉 Industrially Applicable Field
  • This invention relates to a polymer composition containing a poly 1-butene resin as a resin component and its use. More detailedly, this invention relates to a polybutene-1 polymer composition containing a large amount of a filler, which composition is excellent in flexibility and dimensional stability and does not generate poisonous gas if it burns, and a sheet made of the composition. This invention further relates to a flexible sheet suitable, for example as a backing material for carpets, etc.
  • 〈Prior Art〉
  • In recent years, carpets are often used in offices, homes, etc. However, since usual carpets are wide in width and lengthy, they had drawbacks, for example, that they are poor in storability, workability, etc. and, when they are partly stained or scorched, it is hard to repair the part alone. Thus, tile type carpets having a side of the order of 30 to 50 cm were developed. These tile type carpets have various advantages, for example, that they are easy even for non-professionals to install, they can easily be storaged and repaired, and moreover, it is also possible to give a preferred design by changing the arrangement of tile type carpets having a different colors and designs.
  • These tile type carpets are at least required to possesses the characteristics of the following ① to ③.
  • ① To have proper weight and flexibility
  • It is necessary for the carpets to exhibit smoothness even when installed on a floor surface having some unevenness without using an adhesive or the like. Thus, it is necessary for them to have proper weight and flexibility, whereby it is prevented that smoothness is impaired, for example due to partial rise.
  • ② Dimensional stability
  • The temperature of carpets changes over a fairly wide range of from about -5 °C up to about 40 °C depending on the seasons of winter and summer. When tile type carpets have a large linear expansion coefficient, there arise, due to temperature change over such a fairly wide range, inconveniences, for example that gaps arise from the contraction of the carpets at the low temperature time of winter, whereas at the high temperature time of summer they partly rise; and therefore desirably they have a small linear expansion coefficient.
  • ③ Not to generate poisonous gas at the time of combustion
  • In recent years, there is a tendency that many of the causes of death in fires, particularly fires at houses, offices, department stores, etc. are poisoning death due to poisonous gas generated at the time of combustion. Thus, although it is required for the fiber as the body of a carpet to be flame retardant or not to generate poisonous gas even by combustion, a similar property is also required on the backing material itself.
  • Polyvinyl chloride sheets containing calcium carbonate in a high concentration which have hitherto been used as a backing material of carpets can satisfy the above characteristics ① and ②, but are insufficient in the point of the above ③ because they generate chlorine gas or hydrogen chloride gas by combustion. Therefore, materials are demanded which do not generate poisonous gas by combustion.
  • On the other hand, 1-butenic polymers are known to be resins capable of containing a large amounts of a filler, and it is proposed that 1-butenic polymer compositions containing a large amount of a filler can be used, for example as laminates of magnetic tapes, plastic porcelains, floor covering materials or wall covering materials (Refer to Japanese Laid-Open Patent Publication No. 31550/1985).
  • Further, a composition essentially consisting of (a) 5 to 50 weight % of an ethylene-containing copolymer, (b) 2 to 15 weight % of a process oil and 50 to 90 weight % of a filler is proposed, and this composition is proposed to be utilized for sound deadening sheet, carpets having back conating, particularly automotive carpets (Refer to Japanese Laid-Open Patent Publication No. 71734/1980 and US Patent No. 4,263,196).
  • Problems to be Sloved by the Invention
  • However, when a sheet made of a usual 1-butenic polymer composition containing a large amount of a filler was used as a backing material of carpets, it was still insufficient, in flexibility and had a large linear expansion coefficient and thus were insufficient in dimensional stability against temperature change. Further, such a composition contained a large amount of an inorganic filler, and was thus low in fluidity at the time of melting and also had a problem in moldability.
  • Thus, the object of this invention lies in providing a poly(1-butene) resin composition containing a large amount of a filler which is excellent in moldability, flexibility and dimensional stability, and suitable as a raw material of flexible sheets which do not generate poisonous gas by combuston; and a sheet made of it.
  • Another object of this invention lies in providing a tile type carpet having excellent characteristics hereinabove described.
  • Means for Solving the Problems
  • According to researches by the present inventors, it has been found that the objects and advantages of this invention can be accomplished by a polymer composition substantialy comprising
    • (A) 5 to 40 weight parts of a 1-butenic polymer,
    • (B) 95 to 60 weight parts of an inorganic filler,
    • (C) a hydrocarbonic oil in an amount of 2 to 20 weight parts per 100 weight parts in total of the above (A) and (B), and
    • (D) a thermoplastic resin other than 1-butenic polymers in an amount of 0 to 20 weight parts per 100 weight parts in total of the above (A) and (B).
  • The polymer composition of the invention and a sheet made of it are detailedly described below.
  • The 1-butenic polymer (A) as a polymer component of the compositon of the invention is a homopolymer of 1-butene or a copolymer of 1-butene with another α-olefin having 2 to 20 carbon atoms. Examples of another α-olefins having 2 to 20 carbon atoms include, for example, ethylene, propylene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-tetradecene, 1-octadecene, etc. One or two or more of these other α-olefins can be contained in the 1-butenic polymer (A) in a copolymerized form.
  • Further, when the 1-butenic polymer (A) contains another olefin in a copolymerized form, the content is usually 20 mole % or less, preferably 10 mole % or less.
  • The melt flow rate (MFR) of the 1-butenic polymer (A) is such that when the resulting composition is extrusion molded, melt extrusion becomes easy and moldability becomes good, and is 0.01 to 150 g/10 min, preferably 0.05 to 50 g/10 min.
  • This melt flow rate (MFR) is a value measured according to ASTM D 1238, E.
  • Further, the ratio (Mw/Mn) of weight average molecular weight (Mw) to number average molecular weight (Mn) denoting the molecular weight distribution of the 1-butenic polymer (A) is usually in the range of about 2 to about 15, and is preferably in the range of about 3 to about 8 in view of excellence in moldability and mechanical strength.
  • In case where the 1-butenic polymer (A) is a homopolymer, the isotactic index (I.I.) as an index of its stereoregularity is 80 % or more, and is preferably 90 % or more in view of excellence in dimensional stability.
  • This isotactic index (II) is a index measured, by the following method.
  • 1 g of a 1-butenic polymer is dissolved in 100 ml of n-decane, the solution is cooled to 0 °C and left at 0 °C for 24 hours to deposit the highly stereoregular component, and the weight % of the insoluble part is used as the isotactic index (I.I.).
  • The polymer composition of the invention contains a large amount of the inorganic filler (B), as mentioned above. This inorganic filler (B) may be one usually used as a filler for various polymers and may be in a form of powder, flake, short fiber, whisker on the like. Further, the inorganic filler may be any of naturally produced one or the one treated or artificially synthesized one.
  • When the inorganic filler (B) is powder or flake, it is desirable that the average diameter is about 10 to about 1,000 micrometers preferably about 50 to about 500 micrometers. Further, when it is fibrous, it is suitable that it is short fiber having a length of about 7 mm or less, preferably about 5 mm or less.
  • Specific examples of the inorganic filler (B) are, for example, magnesium carbonate, calcium carbonate, clay, kaolin, bentonite, talc, silica, mica, diatom earth, quartz sand, pumice powder, slate powder, asbestos, alumina white, barium sulfate, lithopone, calcium sulfate, molybdenum disulfide, graphite, glass fiber, glass globes, foamed glass globes, fly ash, volcanic glass hollow bodies, synthesized inorganic hollow bodies, single-crystal potassium titanate, carbon black, carbon fiber, carbon hollow bodies, anthracite culm, artificial rock crystal; hydroxides of magnesium, calcium, etc.; vermiculite, graphite; metals such as iron, aluminum and zinc and their oxides; ferrite, etc. There are used solely or in a combination of two or more. Preferred among them are magnesium hydroxide, carbon black, ferrite, mica, talc and calcium carbonate all in the form of powder since they can afford a sheet having further excellent flexibility and smaller linear expansion coefficient.
  • The hydrocarbonic oil (C) in the polymer composition of the invention is liquid at ordinary temperature and may be either one that occurs in nature or synthesized one. Preferred ones among the hydrocarbonic oils (C) are those having compatibility with the 1-butenic polymer, and particularly those having a kinematic viscosity of 30 to 600 cSt (centistokes) at 40°C. Specific examples of the hydrocarbonic oil (C) are, for example, oils comprising paraffinic, naphthenic or aromatic hydrocarbons and mineral oils which are a mixture of the above hydrocarbons; cooligmers of ethylene and an alpha olefin; liquid polybutene, and squalane. These are used alone or in a combination of two or more. Preferred among them are paraffinic process oils and liquid polybutene.
  • The ratio of the above component (B) to the component (A) contained in the polymer composition of the invention is a ratio of 95 to 60 weight parts, preferably 93 to 70 weight parts of the inorganic filler (B) to 5 to 40 weight parts, preferably 7 to 30 weight parts of the 1-butenic polymer (A) in view of the balance of flexibility and linear expansion coefficient.
  • Further, the ratio of the hydrocarbonic oil (C) contained in the polymer composition of the invention is 2 to 20 weight parts, preferably 5 to 15 weight parts per 100 weight parts in total of the 1-butenic polymer (A) and the inorganic filler (B) in view of giving good extrusion moldability and flexibility and causing no inconvenience, for example that the oil bleeds on the resin surface.
  • Further, the polymer composition of the invention can also contain, in a range such that the object of the invention is not spoiled, a thermoplastic resin (D) other than 1-butenic polymers such as polyethylene, polypropylene, polystyrene or an olefinic elastmer, aiming at the improvement of moldability or the adjustment of various physical properties. When the polymer composition of the invention contains such a thermoplastic resin (D), its content is usually in a range of 0 to 20 weight parts per 100 weight parts in total of the 1-butenic polymer (A) and the inorganic filler (B).
  • Still further, the polymer composition of the invention can contain, if necessary, in a range such that the object of the invention is not spoiled, additives such as an antioxidant, an ultraviolet absorber, a fungicide, a rustinhibitor, a lubricant, a filler, a pigment and a heat resistant stabilizer.
  • As for the preparation of the polymer composition of the invention, a granular or pelletized polymer composition can be obtained, for example by mixing the 1-butenic polymer (A), the inorganic filler (B) the hydrocarbonic oil (C) and the thermoplastic resin (D), and if necessary, the above various additives in a conventional mixer such as a Henschel mixer, and melting and kneading the mixture using an extruder.
  • According to the invention, there is provided a sheet made of the above polymer composition and a carpet wherein such a sheet is used as a backing material. The thickness of the sheet is 1 to 5 mm, preferably 2 to 3 mm.
  • The sheet can be molded from the polymer composition according to a method known per se. For example, the molding can be carried out according to a conventional method such as, for example, extrusion molding, injection molding or press molding. In case of the preparation of a carpet, the carpet is prepared by a method wherein a sheet having a thickness of about 1 to 3 mm is continuously molded by extrusion molding and at the same time laminated with a carpet.
  • The polymer composition and a sheet made thereof according to the invention can suitably be used not only as a backing material for carpets, but as a tube material for feed water and drain, a covering material for electric bulbs, and the like.
  • Examples
  • This invention is specifically described below according to examples and comparative examples.
  • In the examples and comparative examples, the tensile Young's modulus (kg/cm²) and linear expansion coefficient (10⁻⁵/°C) of the sheets were measured according to the following methods. Further, the bending test was carried out according to the following method.
  • Tensile Young's modulus
  • The measurement was made according to JIS K 7113.
  • Tensile Young's modulus is a value used as an index of the rigidity of a sheet, and when this value is high, the sheet is hard, and when the value is low, the sheet is soft. When tensile Young's modulus is 5,000 kg/cm² or more, the sheet is inferior in flexibility and unsuitable as a backing material for carpets.
  • Linear expansion coefficient
  • The measurement was made using a thermomechanically analyzing apparatus (produced by Seiko Denshi Kogyo Co., Ltd., TMA 100).
  • The smaller is the linear expansion coefficient, the better is the dimensional stability of the carpet tile, and desirably, the linear expansion coefficient is 15 x 10⁻⁵ (1/°C) or less.
  • Bending test
  • The brittleness of a sheet 3 cm wide, 20 cm long and 3 mm thick was investigated by bending it by hand.
  • It is undesirable to form crazing or crack easily by bending since the carpet will break at the time of the installation of it.
  • Examples 1 to 14 and Comparative Examples 1 to 5
  • The 1-butenic polymer (A), the inorganic filler (B) and the hydrocarbonic oil (C) were mixed in the compounding ratio shown in Table 1 by a Henschel mixer, melted and kneaded at a molding temperature of 200°C using a biaxial extruder, and molded into a sheet having a thickness of about 3 mm by the press molding method. According to the above methods, the resulting sheet was measured for tensile Young's modulus and linear expansion coefficient, and further subjected to the bending test to judge the brittleness of the sheet. The results are shown in Table 1.
    Figure imgb0001
    Figure imgb0002
    Figure imgb0003
    Figure imgb0004
    Figure imgb0005
  • The polymer composition according to this invention is excellent particularly in flexibility and dimensional stability, and suitable as a material of flexible sheets which do not generate poisonous gas even if they are burned. Further, the sheet of the invention made of this polymer composition has such excellent characteristics as above and is particularly suitable as a backing material for tile type carpets.

Claims (12)

  1. A polymer composition substantially comprising
    (A) 5 to 40 weight parts of a 1-butenic polymer,
    (B) 95 to 60 weight parts of an inorganic filler,
    (C) a hydrocarbonic oil in an amount of 2 to 20 weight parts per 100 weight parts in total of the above (A) and (B), and
    (D) a thermoplastic resin other than 1-butenic polymers in an amount of 0 to 20 weight parts per 100 weight parts in total of the above (A) and (B).
  2. The polymer composition of claim 1 wherein the ratio of the 1-butenic polymer (A): the inorganic filler (B) is in a range of 7:93 to 30:70 by weight.
  3. The polymer composition of claim 1 wherein the hydrocarbonic oil (C) is contained in an amount of 5 to 15 weight parts per 100 weight parts in total of the above (A) and (B).
  4. The polymer composition of claim 1 wherein the 1-butenic polymer (A) is a homopolymer of 1-butene or a copolymer of 1-butene with 20 mole % or less of another α-olefin.
  5. The polymer composition of claim 1 wherein the 1-butenic polymer (A) has a melt flow rate of 0.01 to 150 g/10 minutes.
  6. The polymer composition of claim 1 wherein the inorganic filler (B) is powder, flake or short fiber.
  7. The polymer composition of claim 1 wherein the inorganic filler (B) is at least one member selected from the group consisting of magnesium hydroxide, carbon black, ferrite, mica, talc and calcium carbonate all in the form of powder.
  8. The polymer composition of claim 1 wherein the hydrocarbonic oil (C) is liquid at normal temperature and has a kinematic viscosity of 30 to 600 cSt at 40°C.
  9. The polymer composition of claim 1 wherein the hydrocarbonic oil (C) is a paraffinic process oil and/or liquid polybutene.
  10. A sheet made of the polymer composition of claim 1.
  11. A carpet wherein a sheet made of the polymer composition of claim 1 is used as a backing material.
  12. Use of a sheet made of the polymer composition of claim 1 as a backing material.
EP91115553A 1990-09-14 1991-09-13 Polymer composition and its use Expired - Lifetime EP0475434B2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2245009A JP2845594B2 (en) 1990-09-14 1990-09-14 Multi-filled poly 1-butene resin composition and sheet comprising the same
JP245009/90 1990-09-14

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EP0475434A2 true EP0475434A2 (en) 1992-03-18
EP0475434A3 EP0475434A3 (en) 1993-02-24
EP0475434B1 EP0475434B1 (en) 1995-12-06
EP0475434B2 EP0475434B2 (en) 1999-05-19

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CA (1) CA2051332A1 (en)
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EP0742098A1 (en) * 1994-11-30 1996-11-13 Takiron Co. Ltd. Flooring
US6554892B1 (en) 1999-07-02 2003-04-29 Imerys Kaolin, Inc. Compositions and methods for making a coarse platey, high brightness kaolin product
US6758895B2 (en) 2000-08-17 2004-07-06 Imerys Minerals Limited Particulate mineral materials
WO2010080956A1 (en) * 2009-01-08 2010-07-15 Beaulieu Group, Llc Carpet tile having antimicrobial properties and method of manufacturing the same
US8586145B2 (en) 2009-01-07 2013-11-19 Beaulieu Group, Llc Method and treatment composition for imparting durable antimicrobial properties to carpet
WO2020127298A1 (en) * 2018-12-20 2020-06-25 Basell Poliolefine Italia S.R.L. Polyolefin composition for carpet backing

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US5773515A (en) * 1994-08-25 1998-06-30 Solvay Engineered Polymers Engineered polyolefin materials
US5763534A (en) * 1994-08-25 1998-06-09 Solvay Engineered Polymers Thermoplastic polypropylene blends with mixtures of ethylene/butene and ethylene/octene copolymer elastomers
JP2849053B2 (en) * 1995-05-15 1999-01-20 池田物産株式会社 Carpet backing composition and method for producing carpet
GB9807180D0 (en) 1998-04-04 1998-06-03 Ecc Int Ltd Pigment products
AU764156B2 (en) 1999-04-01 2003-08-14 Imerys Pigments, Inc. Kaolin clay pigments, their preparation and use
BR0009458A (en) 1999-04-01 2002-01-08 Imerys Pigments Inc Pigment product for a paper coating composition, processes for making a pigment product for a paper coating composition, and for producing a pigment product, coating composition for use in the production of gloss coatings on paper and others substrates, and, process for coating a sheet of paper and calendering the paper to form a gloss coating on it
IT1313662B1 (en) * 1999-10-12 2002-09-09 Polichem S R L ADDITIVING COMPOSITION FOR ORGANIC POLYMERS AND ITS USE.
GB0020180D0 (en) 2000-08-17 2000-10-04 Imerys Minerals Ltd Kaolin products and their production
GB0020179D0 (en) * 2000-08-17 2000-10-04 Imerys Minerals Ltd Kaolin products and their use
US6983571B2 (en) * 2000-09-29 2006-01-10 Teel Plastics, Inc. Composite roofing panel
US20030085012A1 (en) * 2001-09-07 2003-05-08 Jones J Philip E Hyperplaty clays and their use in paper coating and filling, methods for making same, and paper products having improved brightness
US6808559B2 (en) 2002-02-26 2004-10-26 Imerys Pigments, Inc. Kaolin clay pigments suited to rotogravure printing applications and method for preparing the same
AU2003214460A1 (en) * 2002-03-28 2003-10-13 Imerys Minerals Limited Flame retardant polymer compositions comprising a particulate clay mineral
KR20070087560A (en) * 2004-12-17 2007-08-28 바셀 폴리올레핀 이탈리아 에스.알.엘 Compositions of additives for plastics
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US7735287B2 (en) * 2006-10-04 2010-06-15 Novik, Inc. Roofing panels and roofing system employing the same
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CA135807S (en) 2010-06-04 2011-01-27 Novik Inc Roof or siding shingle panel
JP5466718B2 (en) * 2012-01-27 2014-04-09 積水化学工業株式会社 Method for producing extrusion molded body
CA2838061C (en) 2012-12-19 2016-03-29 Novik Inc. Corner assembly for siding and roofing coverings and method for covering a corner using same
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JP2016074843A (en) * 2014-10-08 2016-05-12 株式会社戸出O−Fit Composite resin material and production method thereof
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US8586145B2 (en) 2009-01-07 2013-11-19 Beaulieu Group, Llc Method and treatment composition for imparting durable antimicrobial properties to carpet
US9493908B2 (en) 2009-01-07 2016-11-15 Beaulieu Group, Llc Method and treatment composition for imparting durable antimicrobial properties to carpet
WO2010080956A1 (en) * 2009-01-08 2010-07-15 Beaulieu Group, Llc Carpet tile having antimicrobial properties and method of manufacturing the same
WO2020127298A1 (en) * 2018-12-20 2020-06-25 Basell Poliolefine Italia S.R.L. Polyolefin composition for carpet backing

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JPH04122752A (en) 1992-04-23
JP2845594B2 (en) 1999-01-13
EP0475434B2 (en) 1999-05-19
DE69115182D1 (en) 1996-01-18
EP0475434A3 (en) 1993-02-24
US5416151A (en) 1995-05-16
CA2051332A1 (en) 1992-03-15
EP0475434B1 (en) 1995-12-06
DE69115182T3 (en) 1999-10-28
DE69115182T2 (en) 1996-05-15

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